New Generation Face Mill Dramatically Reduces Time FEATURES 2-5 times better roughing efficiency than conventional face mills Very stable performace in interrupted cutting Extraordinary metal removal and feed rates Economical four edged insert 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com 7
IntroductIon Hitachi Tool s ASF Face Mills achieve a level of performance that was previously unattainable. The special radius cutting edge allows for extraordinary metal removal rates and dramatically lower roughing times. The chart on the right demonstrates the difference between conventional face mills and the new ASF. In most cases we are able to increase the feed (fz) up to five times without the need to increase the cutting speed (Vc) thus stabilizing or even increasing tool life. ASF Features 1. Unique Radius Cutting Edge The shape of the special insert creates an advantage over round and traditional radius type inserts. The combination of the unique insert and large pockets that assist with chip evacuation allow the ASF Series Face Mills to achieve depths of cut of up to 3mm (0.118"). The inserts also feature four usable cutting edges, therefore increasing the cost efficiency of every insert. Ø 30 mm Ø 1.181" doc = 3.0 mm 0.118" f z 2. Field Data Extraordinary feed rates of up to 3.5mm (0.138") per tooth in steel and 4.0mm (0.158") per tooth in cast iron are achievable. In addition, metal removal rates of 1000cm 3 (61 in 3 ) to 2000cm 3 (122 in 3 ) are possible. This example demonstrates the increased productivity of a 250mm (9.84") ASF Face Mill compared to a conventional radius cutter in stainless steel. Conventional ASF5250R Ø 250 mm (9.84") Ø 250 mm (9.84") 12 teeth 12 teeth Cutting Conditions Cutting Conditions N = 255 rpm N = 115 rpm Vc = 200 m/min (656 sfm) Vc = 90 m/min (295 sfm) Vf = 612 mm/min (24.09 ipm) Vf = 1,380 mm/min (54.33 ipm) fz = 0.2 mm/tooth (0.0079 in/tooth) fz = 1.0 mm/tooth (0.0394 in/tooth) doc = 2 mm (0.079") doc = 2 mm (0.079") woc = 150 mm (5.906") woc = 150 mm (5.906") Q = 184 cm3/min (11.23 in 3 /min) Q = 414 cm3/min (25.26 in 3 /min) Metal Removal 500 400 300 200 100 0 3 11.23 in /min 184 cm 3 /min Conventional 25.26 in 3 /min 414 cm 3 /min ASF Conventional ASF 0 1 2 3 4 5 (piece) Workpiece: AlSI304 Stainless Steel 8 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com
3. Stable Performance Even in Interrupted Cuts The highly rigid design of the ASF Face Mills and inserts provide exceptional performance even in interrupted cuts. In the example below, stable machining of 30HRC prehardened mold steel populated with 8.0mm holes is achieved. Ø 125 mm (4.921") Material: AISI P20V c 150 m/min (492.1 sfm) N = 380 rpm f z = 1.5 mm/tooth (0.0591 in/tooth) Hole Ø 8 mm V f = 540 mm/min (21.26 ipm) (0.315") doc x woc = 1.0 x 90 mm (0.0394" x 3.543") dry cutting 15 min Conventional radius mill ASF (P40) 180~210 min 0 30 90 120 240 (98.4 ft.) (295.3 ft.) (393.7 ft.) (787.4 ft.) (m) Cutting Length L 2013 2009 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com 9
Face Mill Style 50 ROUGHING FINISHING HRC 50 ød2 1 2 ød1 A B ød2 ød1 A B E E H H ød2 R15 ød2 R15 ød1: (D-20) ød ap=3.0 ød1: (D-20) ød ap=3.0 D 0/-0.2 IASF - INCH Part No. Flutes ØD ØD 1 H Ød 1 Ød 2 ØD2 E A B Type Insert IASF5040R 4 2.5 1.713 1.969 1.575 0.75 0.630 2.362 1.024 0.32 0.197 0.630 1 SDNW15, SDMT15, SDEW15 IASF5048R 4 3.0 2.213 2.480 1.969 1.00 0.827 2.756 1.378 0.38 0.236 0.827 1 SDNW15, SDMT15, SDEW15 IASF5064R 5 4.0 3.213 2.756 1.969 1.50 1.969 3.543 1.378 0.63 0.394 1.969 1 SDNW15, SDMT15, SDEW15 IASF5080R 6 5.0 4.213 2.756 2.480 1.50 1.969 3.937 1.378 0.63 0.394 1.969 2 SDNW15, SDMT15, SDEW15 IASF5096R 8 6.0 5.213 2.756 2.480 1.50 2.165 4.134 1.378 0.63 0.394 2.165 2 SDNW15, SDMT15, SDEW15 IASF5128R 10 8.0 7.213 2.756 2.480 2.50 2.165 4.134 5.118 1.378 1.01 0.551 2.165 2 SDNW15, SDMT15, SDEW15 IASF5160R 12 10.0 9.213 2.756 2.480 2.50 5.517 5.118 1.378 1.01 0.551 5.517 2 SDNW15, SDMT15, SDEW15 Inserts p. 12 Part No. Clamp Screw Locator Locator Screw Wedge Screw Wedge Wrench IASF5040R 555-141 105-T20 IASF5048R 555-141 105-T20 IASF5064R 555-141 105-T20 IASF5080R 555-141 351-111 156-161 100-143 176-121 105-T20 IASF5096R 555-141 351-111 156-161 100-143 176-121 105-T20L IASF5128R 555-141 351-111 156-161 100-143 176-121 105-T20L IASF5160R 555-141 351-111 156-161 100-143 176-121 105-T20L 10 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com
Face Mill Style IASF/ASF 50 ROUGHING FINISHING HRC 50 ød2 1 2 ød1 A B ød2 ød1 A B E E H H ød2 R15 ød2 R15 ød1: (D-20) ød ap=3.0 ød1: (D-20) ød ap=3.0 D 0/-0.2 ASF - METRIC Part No. Flutes ØD ØD 1 H Ød 1 Ød 2 ØD 2 E A B Type Insert ASF5063RM 4 63 43 50 22.000 17 60 20.0 10.4 6.3 1 SDNW15, SDMT15, SDEW15 ASF5080RM 4 80 60 63 27.000 20 70 22.0 12.4 7.0 1 SDNW15, SDMT15, SDEW15 ASF5100RM 5 100 80 63 32.000 26 90 25.5 14.4 8.0 1 SDNW15, SDMT15, SDEW15 ASF5125RM 6 125 105 63 40.000 32 100 30.0 16.4 9.0 2 SDNW15, SDMT15, SDEW15 ASF5160R 8 160 140 63 50.800 69 105 38.0 19.0 11.0 2 SDNW15, SDMT15, SDEW15 ASF5200R 10 200 180 63 47.625 105 150 38.0 25.4 14.0 2 SDNW15, SDMT15, SDEW15 Inserts p. 12 Part No. Clamp Screw Locator Locator Screw Wedge Screw Wedge Wrench ASF5063RM 555-141 105-T20 ASF5080RM 555-141 105-T20 ASF5100RM 555-141 105-T20 ASF5125RM 555-141 351-111 156-161 100-143 176-121 105-T20 ASF5160R 555-141 351-111 156-161 100-143 176-121 105-T20L ASF5200R 555-141 351-111 156-161 100-143 176-121 105-T20L 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com 11
Inserts T W W W R SDNW R SDMT with breaker R SDMT with breaker and wiper Part No. R T W Type SDNW1505ZDTN-R15 15 5.56 15.875 A SDMT1505ZDTN-C15 15 5.56 15.875 C SDMT1505ZDTN-R15 15 5.56 15.875 B All inserts have four effective cutting edges COATING MATERIALS FOR INSERTS Material Name Coating Name Coating Type Application Features (P10-M10-K10) (P30-M30-K30) (P30-M30-K30) (P40-M40-K40) (P40-M40) JP Coating PVD JX Coating PVD CY Coating (TiAlN) PVD JS Coating PVD JM coating PVD For cutting of pre-hardened steel (40-50 HRC) General purpose for steel General purpose for steel General purpose for steel For cutting stainless-steel materials Uses coating with excellent shock resistance, making it superior for cutting pre-hardened steel Uses moderate substrate, Multi purpose grade Uses TiAlN coating, has wide cutting range Uses coating with excellent heat resistance and librication characteristics / Has wide cutting range Uses coating with adhesion of membranes to reduce peeling of membranes due to welding. 12 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com
Cutting Conditions Inch Material Mild Steel (200HB) (<30HRC) (30-40HRC) (40-45HRC) (45-50HRC) Ø 2.5" or 63mm (4 Flutes) 3" or 80mm (4 Flutes) 4" or 100mm (5 Flutes) 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com 13 N(rpm) 900 900 1110 710 710 870 570 570 700 Vc(sfm) 591 591 722 591 591 722 591 591 722 Vf(in/min) 213 354 53 168 280 41 169 281 41 fz(in/t) 0.059 0.098 0.012 0.059 0.098 0.012 0.059 0.098 0.012 doc(in) 0.059 0.079 0.012 0.059 0.079 0.012 0.059 0.079 0.012 N(rpm) 900 900 1010 710 710 790 570 570 630 Vc(sfm) 591 591 656 591 591 656 591 591 656 Vf(in/min) 213 354 48 168 280 37 169 281 37 fz(in/t) 0.059 0.098 0.012 0.059 0.098 0.012 0.059 0.098 0.012 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 0.059 0.059 0.012 N(rpm) 800 800 900 630 630 710 500 500 570 Vc(sfm) 525 525 591 525 525 591 525 525 591 Vf(in/min) 189 252 43 149 198 34 148 197 34 fz(in/t) 0.059 0.079 0.012 0.059 0.079 0.012 0.059 0.079 0.012 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 0.059 0.059 0.012 N(rpm) 600 600 750 470 470 590 380 380 470 Vc(sfm) 394 394 492 394 394 492 394 394 492 Vf(in/min) 76 142 35 59 111 28 60 112 28 fz(in/t) 0.031 0.059 0.012 0.031 0.059 0.012 0.031 0.059 0.012 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 0.059 0.059 0.012 N(rpm) 450 450 600 350 350 470 280 280 380 Vc(sfm) 295 295 394 295 295 394 295 295 394 Vf(in/min) 21 35 19 17 28 15 17 28 15 fz(in/t) 0.012 0.020 0.008 0.012 0.020 0.008 0.012 0.020 0.008 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 0.059 0.059 0.012 Stainless Steel N(rpm) 450 450 600 350 350 470 280 280 380 Vc(sfm) 295 295 394 295 295 394 295 295 394 Vf(in/min) 71 106 28 55 83 22 55 83 22 fz(in/t) 0.039 0.059 0.012 0.039 0.059 0.012 0.039 0.059 0.012 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 0.059 0.059 0.012 Cast Iron N(rpm) 800 800 1110 630 630 870 500 500 700 Vc(sfm) 525 525 722 525 525 722 525 525 722 Vf(in/min) 252 378 53 198 298 41 197 295 41 fz(in/t) 0.079 0.118 0.012 0.079 0.118 0.012 0.079 0.118 0.012 doc(in) 0.079 0.079 0.012 0.079 0.079 0.012 0.079 0.079 0.012
Cutting Conditions Inch Material Mild Steel (200HB) (<30HRC) (30-40HRC) (40-45HRC) (45-50HRC) 6" or 160mm (8 Flutes) 8" or 200mm (10 Flutes) N(rpm) 350 350 430 280 280 350 Vc(sfm) 591 591 722 591 591 722 Vf(in/min) 165 276 41 165 276 41 fz(in/t) 0.059 0.098 0.012 0.059 0.098 0.012 doc(in) 0.059 0.079 0.012 0.059 0.079 0.012 N(rpm) 350 350 390 280 280 310 Vc(sfm) 591 591 656 591 591 656 Vf(in/min) 165 276 37 165 276 37 fz(in/t) 0.059 0.098 0.012 0.059 0.098 0.012 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 N(rpm) 310 310 350 250 250 280 Vc(sfm) 525 525 591 525 525 591 Vf(in/min) 146 195 33 148 197 33 fz(in/t) 0.059 0.079 0.012 0.059 0.079 0.012 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 N(rpm) 230 230 290 190 190 230 Vc(sfm) 394 394 492 394 394 492 Vf(in/min) 58 109 28 60 112 27 fz(in/t) 0.031 0.059 0.012 0.031 0.059 0.012 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 N(rpm) 170 170 230 140 140 190 Vc(sfm) 295 295 394 295 295 394 Vf(in/min) 16 27 15 17 28 15 fz(in/t) 0.012 0.020 0.008 0.012 0.020 0.008 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 Stainless Steel N(rpm) 170 170 230 140 140 190 Vc(sfm) 295 295 394 295 295 394 Vf(in/min) 54 80 22 55 83 22 fz(in/t) 0.039 0.059 0.012 0.039 0.059 0.012 doc(in) 0.059 0.059 0.012 0.059 0.059 0.012 Cast Iron N(rpm) 310 310 430 250 250 350 Vc(sfm) 525 525 722 525 525 722 Vf(in/min) 195 293 41 197 295 41 fz(in/t) 0.079 0.118 0.012 0.079 0.118 0.012 doc(in) 0.079 0.079 0.012 0.079 0.079 0.012 10" or 250mm (12 Flutes) 220 220 280 591 591 722 156 260 40 0.059 0.098 0.012 0.059 0.079 0.012 220 220 250 591 591 656 156 260 35 0.059 0.098 0.012 0.059 0.059 0.012 200 200 220 525 525 591 142 189 31 0.059 0.079 0.012 0.059 0.059 0.012 150 150 190 394 394 492 57 106 27 0.031 0.059 0.012 0.059 0.059 0.012 110 110 150 295 295 394 16 26 14 0.012 0.020 0.008 0.059 0.059 0.012 110 110 150 295 295 394 52 78 21 0.039 0.059 0.012 0.059 0.059 0.012 200 200 280 525 525 722 189 283 40 0.079 0.118 0.012 0.079 0.079 0.012 14 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com
Cutting Conditions Metric Material Mild Steel (200HB) (<30HRC) (30-40HRC) (40-45HRC) (45-50HRC) Ø 2.5" or 63mm (4 Flutes) 3" or 80mm (4 Flutes) 4" or 100mm (5 Flutes) N(rpm) 900 900 1110 710 710 870 570 570 700 Vc(m/min) 180 180 220 180 180 220 180 180 220 Vf(mm/min) 5400 9000 1340 4260 7100 1050 4280 7130 1050 fz(mm/t) 1.50 2.50 0.30 1.50 2.50 0.30 1.50 2.50 0.30 doc(mm) 1.5 2 0.3 1.5 2 0.3 1.5 2 0.3 N(rpm) 900 900 1010 710 710 790 570 570 630 Vc(m/min) 180 180 200 180 180 200 180 180 200 Vf(mm/min) 5400 9000 1220 4260 7100 950 4280 7130 950 fz(mm/t) 1.50 2.50 0.30 1.50 2.50 0.30 1.50 2.50 0.30 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 1.5 1.5 0.3 N(rpm) 800 800 900 630 630 710 500 500 570 Vc(m/min) 160 160 180 160 160 180 160 160 180 Vf(mm/min) 4800 6400 1080 3780 5040 860 3750 5000 860 fz(mm/t) 1.50 2.00 0.30 1.50 2.00 0.30 1.50 2.00 0.30 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 1.5 1.5 0.3 N(rpm) 600 600 750 470 470 590 380 380 470 Vc(m/min) 120 120 150 120 120 150 120 120 150 Vf(mm/min) 1920 3600 900 1510 2820 710 1520 2850 710 fz(mm/t) 0.80 1.50 0.30 0.80 1.50 0.30 0.80 1.50 0.30 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 1.5 1.5 0.3 N(rpm) 450 450 600 350 350 470 280 280 380 Vc(m/min) 90 90 120 90 90 120 90 90 120 Vf(mm/min) 540 900 480 420 700 380 420 700 380 fz(mm/t) 0.30 0.50 0.20 0.30 0.50 0.20 0.30 0.50 0.20 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 1.5 1.5 0.3 Stainless Steel N(rpm) 450 450 600 350 350 470 280 280 380 Vc(m/min) 90 90 120 90 90 120 90 90 120 Vf(mm/min) 1800 2700 720 1400 2100 570 1400 2100 570 fz(mm/t) 1.00 1.50 0.30 1.00 1.50 0.30 1.00 1.50 0.30 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 1.5 1.5 0.3 Cast Iron N(rpm) 800 800 1110 630 630 870 500 500 700 Vc(m/min) 160 160 220 160 160 220 160 160 220 Vf(mm/min) 6400 9600 1340 5040 7560 1050 5000 7500 1050 fz(mm/t) 2.00 3.00 0.30 2.00 3.00 0.30 2.00 3.00 0.30 doc(mm) 2 2 0.3 2 2 0.3 2 2 0.3 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com 15
Cutting Conditions Metric Material Mild Steel (200HB) (<30HRC) (30-40HRC) (40-45HRC) (45-50HRC) 6" or 160mm (8 Flutes) 8" or 200mm (10 Flutes) N(rpm) 350 350 430 280 280 350 Vc(m/min) 180 180 220 180 180 220 Vf(mm/min) 4200 7000 1040 4200 7000 1050 fz(mm/t) 1.50 2.50 0.30 1.50 2.50 0.30 doc(mm) 1.5 2 0.3 1.5 2 0.3 N(rpm) 350 350 390 280 280 310 Vc(m/min) 180 180 200 180 180 200 Vf(mm/min) 4200 7000 940 4200 7000 930 fz(mm/t) 1.50 2.50 0.30 1.50 2.50 0.30 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 N(rpm) 310 310 350 250 250 280 Vc(m/min) 160 160 180 160 160 180 Vf(mm/min) 3720 4960 840 3750 5000 840 fz(mm/t) 1.50 2.00 0.30 1.50 2.00 0.30 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 N(rpm) 230 230 290 190 190 230 Vc(m/min) 120 120 150 120 120 150 Vf(mm/min) 1480 2760 700 1520 2850 690 fz(mm/t) 0.80 1.50 0.30 0.80 1.50 0.30 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 N(rpm) 170 170 230 140 140 190 Vc(m/min) 90 90 120 90 90 120 Vf(mm/min) 410 680 370 420 700 380 fz(mm/t) 0.30 0.50 0.20 0.30 0.50 0.20 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 Stainless Steel N(rpm) 170 170 230 140 140 190 Vc(m/min) 90 90 120 90 90 120 Vf(mm/min) 1360 2040 560 1400 2100 570 fz(mm/t) 1.00 1.50 0.30 1.00 1.50 0.30 doc(mm) 1.5 1.5 0.3 1.5 1.5 0.3 Cast Iron N(rpm) 310 310 430 250 250 350 Vc(m/min) 160 160 220 160 160 220 Vf(mm/min) 4960 7440 1040 5000 7500 1050 fz(mm/t) 2.00 3.00 0.30 2.00 3.00 0.30 doc(mm) 2 2 0.3 2 2 0.3 10" or 250mm (12 Flutes) 220 220 280 180 180 220 3960 6600 1010 1.50 2.50 0.30 1.5 2 0.3 220 220 250 180 180 200 3960 6600 900 1.50 2.50 0.30 1.5 1.5 0.3 200 200 220 160 160 180 3600 4800 800 1.50 2.00 0.30 1.5 1.5 0.3 150 150 190 120 120 150 1440 2700 690 0.80 1.50 0.30 1.5 1.5 0.3 110 110 150 90 90 120 400 660 360 0.30 0.50 0.20 1.5 1.5 0.3 110 110 150 90 90 120 1320 1980 540 1.00 1.50 0.30 1.5 1.5 0.3 200 200 280 160 160 220 4800 7200 1010 2.00 3.00 0.30 2 2 0.3 16 2013 Hitachi Tool Engineering, Ltd. ph 800 333 1514 www.hitachitoolusa.com